WO1999056588A2

WO1999056588A2 - An improved fabric for bedding products and upholstered furniture

Info

Publication number: WO1999056588A2
Application number: PCT/US1999/009762
Authority: WO
Inventors: Ryner D. Wittgens
Original assignee: National Allergy Supply Inc.
Priority date: 1998-05-07
Filing date: 1999-05-04
Publication date: 1999-11-11
Also published as: WO1999056588A3; AU3880899A

Abstract

The present invention is a cover for a bedding product which includes a multi-layer non-woven fabric (10) that forms an interior lining of a casing (30) for the bedding product. The lining and casing is formed to encase the bedding product which may be a mattress (49), pillow, or other product. The cover includes an outer fabric layer (34) such as flannel, cotton, satin that is integrally attached to the multilyer non-woven fabric lining (10). The fabric layer (34) will be matched to the fabric used in the remainder of a complete set of bedding. In another embodiment a cover is provided for an item of upholstered furniture (50). The cover includes a sunbond--melt blown--spunbond laminate fabric (52, 54, 56) that is integrally attached to an outer fabric layer (58). The resulting cover is sized and shaped to cover the furniture item (50). The invention provides an inner lining for a bedding product or funiture item that provides a breathable barrier against dust mites.

Description

AN IMPROVED FABRIC FOR BEDDING PRODUCTS AND UPHOLSTERED FURNITURE

BACKGROUND OF THE INVENTION Field of the Invention

The present invention generally relates to covers for upholstered furniture and bedding products, and more particularly to an improved cover for furniture items and bedding products that provides an effective barrier for dust mites and their associated allergen. Discussion of the Related Art

Many people suffer from allergies caused by airborne fine particulate matter, such as pollen, dust, dust mites, feathers, pet dander, molds, etc. It has been found that many of allergy sufferers and asthma sufferers are allergic to house dust and dust mites that live in the dust. As is known, the house dust mite is a member of the spider family and measures about 0.3 millimeters across. At this size it is virtually indistinguishable from a speck of dust. It has been found that the dust mite itself does not generally cause allergic reactions. Instead, it is part of the dust mite fecal pellet, which measures about 20 microns in diameter, that causes allergic reactions. This allergic part of the dust mite fecal pellet becomes airborne and may be inhaled and deposited on the inner lining of the respiratory tract of an allergy sufferer, thereby triggering a reaction.

Dust mites are most concentrated in areas like beds and bedding, pillows, couches, etc. In this regard, the house dust mite feeds on human skin scales. Since it needs to obtain moisture from the air, it is found mostly in warm, moist areas, such as bedding and upholstered furniture. Existing protective covering, such as rubber or plastic sheets for beds, have the disadvantage that, although they would trap the microscopic particles, they do not allow transpiration of moisture which causes great discomfort to the user. In this regard, bedding products (such as mattress and pillow covers) are known that provide a polyurethane coating on the interior of a fabric (such as nylon). While polyurethane coatings may be vapor penetrable, they provide little to no breathability. This leads to discomfort for the user. In addition, they are often characterized as having a rigid, or crinkled feel, which makes them disfavored as a pillow covering or mattress encasing.

Accordingly, there is a desire to provide an improved bedding fabric that overcome these or other shortcomings known in the prior art. SUMMARY OF THE INVENTION

Certain objects, advantages and novel features of the invention will be set forth in part in the description that follows and in part will become apparent to those skilled in the art upon examination of the following or may be learned with the practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the appended claims.

To achieve the advantages and novel features, the present invention is generally directed to a cover for a bedding product. In accordance with one aspect of the invention, the cover includes a multi-layer non-woven fabric that defines an interior lining of an encasing for a bedding product. This lining, and the encasing in general, is formed to substantially encase the bedding product, whether it be a mattress, pillow, or other product. The cover further includes an outer fabric that is integrally attached to the multi-layer non-woven fabric lining. The outer layer may be comprised of any suitable fabric, such as flannel, cotton, satin, etc. For example, if the cover is a pillow cover, the outer fabric should be such that it matches the material of the remainder of the linen set. Thus, if it is a pillow case for a set of cotton sheets, then the outer layer will preferably be cotton. If it is a pillow case for a set of flannel sheets, then the outer layer will preferably be flannel. In accordance with another aspect of the invention, a cover is provided for an item of upholstered furniture. In accordance with this aspect of the invention, the cover includes a spunbond—melt-blown— spunbond laminate fabric that is integrally attached to an outer fabric. The two fabrics, together, are then particularly sized and shaped to cover the item of furniture. It will be appreciated that the item of furniture may be a sofa, a chair, a love-seat, an ottoman, or other furniture item. The outer layer of fabric may be cloth, or other fabric, depending on the furniture. In this regard, the invention provides an inner lining for an otherwise upholstered item of furniture, whereby the inner lining provides a breathable, but effective barrier against dust mites. DESCRIPTION OF THE DRAWINGS The accompanying drawings incorporated in and forming a part of the specification, illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention. In the drawings:

FIG. 1 A is a perspective view of a sheet or web of a multi-layer, non- woven material utilized in the preferred embodiment of the present invention; FIG. IB is a cross-sectional side view of the material of FIG. 1A, taken at a bonding point; FIG. 2A is a perspective view of a pillow casing constructed in accordance with a first embodiment of the present the invention;

FIG. 2B is a cross-sectional view of the pillow casing of FIG. 2 A, as taken substantially along line 2B-2B; FIG. 2C is a perspective view of a pillow casing constructed in accordance with a second embodiment of the present invention;

FIG. 3 A is a perspective view of a mattress encasing constructed in accordance with an embodiment of the present invention;

FIG. 3B is a cross-sectional view of the mattress encasing of FIG. 3A, as taken substantially along line 3B-3B;

FIG. 4 is a perspective view of an upholstered chair, constructed in accordance with an embodiment of the present invention;

FIG. 5 A is a perspective view of a bedding comforter, constructed in accordance with an embodiment of the present invention; and FIG. 5B is a cross-sectional view of the comforter of FIG. 5 A, as taken substantially along line 5B-5B. DEFINITIONS

Before describing the preferred embodiment of the present invention, several definitions are set out immediately below. To the extent that these terms may have a particular meaning, as a term or art or otherwise, that differs from the definitions set out below, the definitions shall control the interpretation and meaning of the terms as used within the specification and claims herein, unless the specification or claims expressly assigns a differing or more limited meaning to a term in a particular location or for a particular application. NON-WOVEN FABRIC - refers to a fabric or web having a structure of individual fibers or threads which are interlaid, but not in an identifiable manner as in a knitted fabric. Non-woven fabrics or webs have been formed from many processes such as for example, meltblowing processes, spunbonding processes, and bonded carded web processes. The basis weight of non-woven fabrics is usually expressed in ounces of material per square yard (osy) or grams per square meter (gsm) and the fiber diameters useful are usually expressed in microns.

MICRO-FIBERS - refers to small diameter fibers having an average diameter not greater than about 50 microns, for example, having an average diameter of from about 0.5 microns to about 50 microns. More specifically, micro-fibers may desirably have an average diameter of from about 2 microns to about 40 microns.

SPUNBONDED FIBERS - refers to small diameter fibers which are formed by extruding molten thermoplastic material as filaments from a plurality of fine, usually circular capillaries of a spinnerette with the diameter of the extruded filaments then being rapidly reduced. Spunbond fibers are generally continuous and larger than 7 microns. More specifically, spunbond fibers generally have an average diameter of greater than 10 microns.

MELT-BLOWN FIBERS - refers to fibers formed by extruding a molten thermoplastic material through a plurality of fine, usually circular, die capillaries as molten threads or filaments into a high velocity, usually heated gas (e.g, . air) stream which attenuates the filaments of molten , thermoplastic material to reduce their diameter, which may be to micro-fiber diameter. Thereafter, the melt-blown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly disbursed melt-blown fibers. Melt-blown fibers are micro- fibers which are generally smaller than 10 microns in diameter. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Having summarized various aspects of the present invention, reference will now be made in detail to the description of the invention as illustrated in the drawings. While the invention will be described in connection with these drawings, there is no intent to limit it to the embodiment or embodiments disclosed therein. On the contrary, the intent is to cover all alternatives, modifications and equivalents included within the spirit and scope of the invention as defined by the appended claims.

The present invention employs the use of a non-woven material fabric for providing a dust mite barrier for, for example, upholstered furniture, pillows, mattresses, comforters, etc. Non-woven fabrics provide a lower cost alternative to woven fabrics and are used for a wide variety of applications from baby wipes and diapers to automobile covers. These diverse applications call for materials having diverse properties and attributes. Some applications, for example, call for non- wovens which are highly wettable. That is, materials that allow liquids to quickly pass through them, such as liners for diapers and feminine hygiene products. Other non-woven fabrics require a high degree of repellency, such as outdoor fabrics and surgical fabrics. It is the latter class of products with which this invention is concerned. Specifically, the present invention is directed to non-woven materials that have superior barrier properties yet which have a high degree of vapor breathability.

Fabrics for bedding applications, such as a pillow case, must have good barrier properties in order to protect against the passage of dust mites and their associated allergens, yet must be breathable in order for the wearer's perspiration to pass through the fabric so as to remain comfortable during sleep. The fabric must also be strong enough to perform the desired function in the appropriate environment yet be soft and flexible for the person's comfort.

In this regard, the present invention utilizes a fabric laminate known as SMS, which is formed from spun-bonded/melt-blown/spun-bonded (SMS) laminates consisting of non- woven outer layers of spun-bonded polypropylene and an interior barrier layer of melt-blown polypropylene. Such SMS fabric laminates have durable outside "spun-bonded" layers, and an internal "melt-blown" barrier layer, which is porous to allow breathability, but which has been found to inhibit the passage of dust mites and their associated allergens. Thus, in order for such a fabric to perform properly, it is preferred that the melt-blown barrier layer have a fiber size and a pore size distribution that assures breathability of the fabric.

Non-woven fabrics are generally bonded in some manner as they are produced in order to give them sufficient structural integrity to withstand the rigors of further processing into a finished product. Bonding can be accomplished in a number of ways such as hydroentanglement, needling, ultrasonic bonding, and adhesive bonding.

Thermal bonding is utilized in the preferred embodiment of the present invention and may be fabricated by passing the non-woven fabric between the rolls of a calendering machine. Typically, least one of the rollers of the calender is heated and at least one of the rollers, not necessarily the same one as the heated one, has a pattern which is imprinted upon the non- woven fabric as it passes between the rollers. As the fabric passes between the rollers it is subjected to pressure as well as heat. The combination of heat and pressure applied in a particular pattern results in the creation of fused bond areas (also known as melt points) in the non-woven fabric where the bonds on the fabric correspond to the pattern of bond points on the calender roll. To more particularly describe this material, reference is made to FIGS. 1A and

IB, which show a perspective and a cross-sectional view of this SMS material 10. The cross-sectional view of FIG. IB is taken at a melt point 12. The, fabric 10 of this invention is a multilayer, SMS laminate. Such a laminate 10 may be made by sequentially depositing onto a moving forming belt first a spunbond fabric layer 14, then a melt-blown fabric layer 16 and last another spunbond layer 18 and then bonding the laminate in a manner described below. Alternatively, the fabric layers may be made individually, collected in rolls, and combined in a separate bonding step.

As will be appreciated, the bonding rolls (not shown) are heated to the softening temperature of the polymer used to form the layers of the web 10. As the web 10 passes between the heated bonding rolls, the material is compressed and heated by the bonding rolls in accordance with the pattern on the rolls to create a pattern of discrete areas, such as 12 shown in FIGS. 1A and IB, which areas are bonded from layer to layer and are bonded with respect to the particular filaments and/or fibers within each layer 14, 16, and 18. Such discrete area or spot bonding is well known in the art and can be carried out as described by means of heated rolls or by means of ultrasonic heating of the web 10 to produced discrete area thermally bonded filaments, fibers, and layers. It is preferable for the fibers of the melt-blown layer in the fabric laminate to fuse within the bond areas while the filaments of the spun-bonded layers retain their integrity in order to achieve good strength characteristics. The fibers from which the fabric of this invention is made may be produced by the meltblowing or spunbonding processes which are well known in the art. These processes generally use an extruder to supply melted thermoplastic polymer to a spinnerette where the polymer is fiberized to yield fibers which may be staple length or longer. The fibers are then drawn, usually pneumatically, and deposited on moving foraminous mat or belt to form the non-woven fabric. The fibers produced in the spunbond and melt-blown processes are micro-fibers as defined above.

As is known, and illustrated in the figures, the fibers of the SMS laminate 10 provide an economical but strong non-woven material that is sufficiently porous to allow breathability (for comfort), yet provide an adequate barrier for dust mites. As previously mentioned, dust mites tend to migrate toward dark places.

Thus, they are known to go to the base of a carpet, or into bedding such as pillows, mattresses and into furniture. Accordingly, the present invention has application in each of these areas. To briefly discuss another such application, brief reference is made to FIGS. 2A and 2B, which illustrate the use of the present invention in a pillow case 30. Preferably, the case 30 will be formed as most conventional pillow cases, being seamed along three sides and open at one end to for a mouth 32, through which a pillow may be inserted or retracted. A zipper (not shown) may be provided along the mouth 32 to provide a sealed closure at that end.

FIG. 2B, which presents a cross-sectional side view taken substantially along line 2B-2B of FIG. 2 A, illustrates the use of the multi-layer SMS laminate in pillow encasing 30. In this regard, a portion of the figure is exploded to exaggerate the different layers 14, 16, and 18 for illustration purposes. In addition, an outer layer 34 is also provided. This outer layer will be integrally attached in any of a number of conventional ways to the SMS laminate 10, to form a unitary pillow case 30. The outer layer may be fabricated from cotton, flannel, satin, or any other suitable or appropriate material. Typically, the material used for layer 34 will be selected to match a linen set. Thus, for example, if the pillow case 30 is sold with a cotton sheet set, then the outer layer 34 will preferably be cotton. If the pillow case 30 is sold with a flannel sheet set, then the outer layer 34 will preferably be flannel.

For purposes of effective operation of the present invention, the pillow case will form an effective seal or enclosed barrier against dust mites. As mentioned above, this enclosed barrier may be completed by a zipper (not shown) disposed to close the mouth 32 of the pillow case 30. Alternatively, a differing pillow configuration may be provided.

In this regard, reference is made briefly to FIG. 2C, which illustrates one such alternative embodiment. In this embodiment, the pillow case 36 is sealed at both ends. Instead, the mouth for receiving the pillow is formed along the mid-section of the pillow case 36. An effective enclosed barrier may be formed by overlapping portions of the pillow casing. For example, a given length 38 of overlap may be provided, sufficient to seal a pillow within the encasing 36, without the passage of dust mites.

Although not separately illustrated in the drawings, it will be appreciated that the present invention is also applicable to a pillow, as well as a pillow casing. The pillow casings illustrated in the drawings depict the application of the present invention in a removable outer fabric encasing for a pillow. However, consistent with the concepts and teachings of the invention, the pillow itself may be constructed from the multi- layer non- woven fabric of the invention. Such an embodiment will effectively prevent the passage of dust mites and their associated allergens to and from the interior of the pillow.

Reference is now made to FIGS. 3 A and 3B, which illustrate another aspect of the present invention. In accordance with this aspect of the invention, the SMS laminate is used to provide a dust mite barrier to a mattress encasing 40. In this regard, the mattress encasing 40 has a split 42 that preferably extends along an edge of the encasing. In such an embodiment, the split 42 extends at least the full length of one side of the encasing, and partially down each adjacent side 43, for example to the point labeled A. Alternatively, the split may extend completely around three sides of the encasing 40 to the point labeled B. Such an embodiment facilitates the placement of the encasing about a mattress 49 (See FIG. 3B). It should be appreciated, however, that for purposes of the invention, the location of the slit 42 or other mechanism that allows or facilitates the placement of the encasing about a mattress is irrelevant. Instead, what is important is that the encasing 40 will be constructed of an SMS laminate as discussed below. Referring briefly to FIG. 3B, a cross-sectional side view of the mattress encasing 40 of FIG. 3 A as taken substantially along line 3B-3B is shown. The figure illustrates the encasing 40 surrounding a centrally disposed mattress 49. In a manner similar to that described in connection with the pillow case above, the encasing 40 comprises four layers 45, 46, 47, and 48 of material. Three layers, 45, 46, and 47 collectively comprise the SMS laminate described above, while the fourth, outer layer comprises some other material, such as cotton, flannel, satin, etc. As described above, this outer fabric will preferably be selected in accordance with the material fabric of a betting/linen set. Like the pillow casing embodiment discussed above, the mattress encasing may be designed to be separate and removable from a mattress 49, or may be integrally formed with the mattress, as an outer lining or fabric thereof.

Reference is now made to FIG. 4, which shows yet another embodiment of the present invention. In this regard, FIG. 4 illustrates the use of the SMS laminate in connection with the outer covering of an item of upholstered furniture, such as a chair 50. Of course, the chair 50 preferably would be constructed in accordance with conventional techniques. The fabric covering, however, would include the SMS laminate material. A small section of this fabric is shown as exploded to illustrate this aspect. Specifically, the fabric covering of the piece of furniture 50 would comprise the three layers 52, 54, and 56 that comprise the SMS laminate, as described above, while an outer layer 58 would be comprised of the preferred, exposed material. In this manner, and effective barrier is provided to guard against dust mites penetrating into the interior of the furniture 50.

Reference is now made to FIGS. 5A and 5B, which illustrate yet another aspect of the invention. In accordance with this aspect of the invention, the SMS laminate described above is used in connection with a comforter 60. The dashed lines 62 represent quilting seams. As is known, a comforter generally includes a soft quilting or insulating material 64. It is within this material that dust mites often burrow. Accordingly, it is desired to provide a barrier to the comforter 60 that prevents the entry of dust mites into this area. Thus, in accordance with the invention, an outer material is provided having a number of layers 65, 66, 67, and 68 (illustrated partially exploded). This layered material includes layers 65, 66, and 67 of the SMS laminate, as described above (See FIG. IB). Further, an outer layer 67 is preferably provided and comprising a different fabric. In this regard, and as described above, this outer layer 67 may be cotton, flannel, satin, nylon, wool, or any other material desired. Consistent with the concepts and teachings of the invention, a comforter cover may be provided having the multi-layer, non- woven fabric described above. In this regard, such an encasing would be constructed much like the encasing for the pillow (See FIG. 2A) of the mattress encasing (See FIG. 3A). Consistent with yet another aspect of the invention, the various embodiments discussed above may be implemented using an alternative material. In this regard, the various embodiments may be implemented using a material that is known for use as a curtain backing. Specifically, the material is known as Special Suede, and is manufactured by Rockland Industries of Baltimore Maryland. In accordance with the present invention, the material may be coated to a natural or synthetic fiber, such as cotton or a cotton blend. It is a soft, flexible material that forms a sufficient barrier to the passage of dust mites and their associated allergens, yet has adequate breathability and vapor transmission to provide comfort to users.

The foregoing description has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiment or embodiments discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly and legally entitled.

Claims

What is Claimed is:

1. A cover for a bedding product comprising: a multi-layer non-woven fabric defining an interior lining that is formed to substantially encase the bedding product; and an outer fabric integrally attached to the multi-layer non-woven fabric lining.

2. The cover as defined in claim 1, wherein the multi-layer non- woven fabric lining is an spunbondΓÇömelt-blownΓÇöspunbond laminate.

3. The cover as defined in claim 1, wherein the bedding product is one selected from the group consisting of: a pillow, a mattress, and a comforter.

4. The cover as defined in claim 1 , wherein the outer fabric is cotton.

5. An improved pillow case providing a protective barrier for dust mites comprising: a spunbondΓÇömelt-blownΓÇöspunbond laminate fabric seamed along three sides to define an encasing sized and shaped to receive a pillow and substantially encase the pillow therein.

6. The pillow case as defined in claim 5, further including a zipper attached to the fourth side and configured to captively retain a pillow disposed therein.

7. The pillow case as defined in claim 5, further including an outer fabric integrally attached to the non- woven fabric.

8. The pillow case as defined in claim 7, wherein the outer fabric is cotton.

9. An improved mattress encasing providing a protective barrier for dust mites comprising: a spunbondΓÇömelt-blownΓÇöspunbond laminate fabric seamed along at least one of four sides, and a means for releasably sealing the remaining three sides, the mattress encasing being sized and shaped to conformingly encase a mattress.

10. The mattress encasing as defined in claim 9, further including an outer fabric integrally attached to the non-woven fabric.

11. A cover for an item of upholstered furniture comprising a spunbond- melt-blownΓÇö spunbond laminate integrally attached to an outer fabric that is particularly sized and shaped and attached to an item of furniture.

12. The cover as defined in claim 11 , wherein the item of furniture is one selected from the group consisting of a sofa, a chair, a love-seat, and an ottoman.

13. A comforter for a bed comprising an inner material, a spunbond-melt- blown-spunbond laminate surrounding the inner material, and an outer fabric that is integrally attached to the laminate.

14. An improved pillow providing a protective barrier for dust mites comprising: a spunbondΓÇömelt-blownΓÇöspunbond laminate fabric configured to define an outer encasing for the pillow.

15. An improved mattress providing a protective barrier for dust mites comprising: a spunbondΓÇömelt-blownΓÇöspunbond laminate fabric configured to define an outer encasing for the mattress.

16. The mattress as defined in claim 15, wherein the spunbondΓÇömelt-blownΓÇö spunbond laminate fabric is disposed as an inner lining to the mattress.